Solar cell modules comprising encapsulant sheets with low haze and high moisture resistance

ABSTRACT

A solar cell module comprising a solar cell layer and an ionomer sheet comprising a sodium/zinc mixed ionomer that is the neutralization product of a precursor acid copolymer; wherein the precursor acid copolymer comprises copolymerized units of an α-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt % of copolymerized units of an α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms based on the total weight of the precursor acid copolymer; wherein the precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min, as determined in accordance with ASTM D1238 at 190° C. and 2.16 kg; and wherein when about 40% to about 90% of the total content of the carboxylic acid groups present in the precursor acid copolymer are neutralized to carboxylate groups to comprise carboxylate groups and counterions that consist essentially of sodium ions, the resulting sodium ionomer has a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry in accordance with ASTM D3418.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Appln. No. 61/141,752, filed on Dec. 31, 2008, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The invention relates to a solar cell module having an encapsulant sheet with low haze and high moisture resistance.

BACKGROUND OF THE INVENTION

Because solar cells provide a sustainable energy resource, their use is rapidly expanding. Solar cells are typically categorized into two types based on the light absorbing material used, i.e., bulk or wafer-based solar cells and thin film solar cells.

Monocrystalline silicon (c-Si), poly- or multi-crystalline silicon (poly-Si or mc-Si) and ribbon silicon are the materials used most commonly in forming the more traditional wafer-based solar cells. Solar cell modules derived from wafer-based solar cells often comprise a series of self-supporting wafers (or cells) that are soldered together. The wafers generally have a thickness of between about 180 and about 240 μm. Such a panel of solar cells is called a solar cell layer and it may further comprise electrical wirings such as cross ribbons connecting the individual cell units and bus bars having one end connected to the cells and the other exiting the module. The solar cell layer is then further laminated to encapsulant layer(s) and protective layer(s) to form a weather resistant module that may be used for at least 20 years. In general, a solar cell module derived from wafer-based solar cell(s) comprises, in order of position from the front sun-facing side to the back non-sun-facing side: (1) an incident layer (or front sheet), (2) a front encapsulant layer, (3) a solar cell layer, (4) a back encapsulant layer, and (5) a backing layer (or backsheet). In such modules, it is essential that the materials positioned to the sun-facing side of the solar cell layer (i.e., the incident layer and the front encapsulant layer) have good transparency to allow sufficient sunlight reaching the solar cells. In addition, some modules may comprise bifacial solar cells, where the solar cells are able to generate electrical power by receiving sunlight directly reaching the sun-facing side thereof and by receiving sunlight that is reflected back to the non-sun-facing side thereof. In such modules it is essential that all the materials surrounding the solar cell layer be sufficiently transparent.

The increasingly important alternative thin film solar cells are commonly formed from materials that include amorphous silicon (a-Si), microcrystalline silicon (μc-Si), cadmium telluride (CdTe), copper indium selenide (CuInSe₂ or CIS), copper indium/gallium diselenide (CuIn_(x)Ga_((1-x))Se₂ or CIGS), light absorbing dyes, and organic semiconductors. By way of example, thin film solar cells are disclosed in e.g., U.S. Pat. Nos. 5,507,881; 5,512,107; 5,948,176; 5,994,163; 6,040,521; 6,137,048; and 6,258,620 and U.S. Patent Publication Nos. 20070298590; 20070281090; 20070240759; 20070232057; 20070238285; 20070227578; 20070209699; and 20070079866. Thin film solar cells with a typical thickness of less than 2 μm are produced by depositing the semiconductor layers onto a superstrate or substrate formed of glass or a flexible film. During manufacture, it is common to include a laser scribing sequence that enables the adjacent cells to be directly interconnected in series, with no need for further solder connections between cells. As with wafer cells, the solar cell layer may further comprise electrical wirings such as cross ribbons and bus bars. Similarly, the thin film solar cells are further laminated to other encapsulant and protective layers to produce a weather resistant and environmentally robust module. Depending on the sequence in which the multi-layer deposition is carried out, the thin film solar cells may be deposited on a superstrate that ultimately serves as the incident layer in the final module, or the cells may be deposited on a substrate that ends up serving as the backing layer in the final module. Therefore, a solar cell module derived from thin film solar cells may have one of two types of construction. The first type includes, in order of position from the front sun-facing side to the back non-sun-facing side, (1) a solar cell layer comprising a superstrate and a layer of thin film solar cell(s) deposited thereon at the non-sun-facing side, (2) a (back) encapsulant layer, and (3) a backing layer. The second type may include, in order of position from the front sun-facing side to the back non-sun-facing side, (1) an incident layer, (2) a (front) encapsulant layer, (3) a solar cell layer comprising a layer of thin film solar cell(s) deposited on a substrate at the sun-facing side thereof.

The encapsulant layers used in solar cell modules are designed to encapsulate and protect the fragile solar cells. Suitable polymer materials for solar cell encapsulant layers typically possess a combination of characteristics such as high impact resistance, high penetration resistance, good ultraviolet (UV) light resistance, good long term thermal stability, adequate adhesion strength to glass and other rigid polymeric sheets, high moisture resistance, and good long term weatherability.

Ionomers are copolymers produced by partially or fully neutralizing the carboxylic acid groups of precursor or parent polymers that are acid copolymers usually comprising copolymerized residues of α-olefins and α,β-ethylenically unsaturated carboxylic acids. In recent years, certain types of ionomers have been used as solar cell encapsulant materials. See, e.g., U.S. Pat. Nos. 5,476,553; 5,478,402; 5,733,382; 5,741,370; 5,762,720; 5,986,203; 6,114,046; 6,187,448; 6,353,042; 6,320,116; and 6,660,930, and U.S. Patent Publication Nos. 2003/0000568 and 2005/0279401. More recently, ionomers with excellent optical properties have also been explored as solar cell encapsulant materials, such as those disclosed in Applicants' co-pending applications 61/110,486 (filed on Oct. 31, 2008) and patent application entitled SOLAR CELLS MODULES COMPRISING LOW HAZE ENCAPSULANTS, filed Dec. 30, 2008. However, there is still a need to develop an ionomeric encapsulant material having not only good optical properties, but also improved moisture resistance.

SUMMARY OF THE INVENTION

The invention is directed to a solar cell module comprising a solar cell layer and an ionomer sheet, wherein,

-   -   (A) the solar cell layer comprises a single solar cell or a         plurality of electrically interconnected solar cells and;     -   (B) the ionomer sheet comprises a sodium/zinc mixed ionomer that         is the neutralization product of a precursor acid copolymer;         wherein the precursor acid copolymer comprises copolymerized         units of an α-olefin having 2 to 10 carbon atoms and about 20 to         about 30 wt % of copolymerized units of an α,β-ethylenically         unsaturated carboxylic acid having 3 to 8 carbon atoms, based on         the total weight of the precursor acid copolymer; wherein the         precursor acid copolymer has a melt flow rate of about 70 to         about 1000 g/10 min, as determined in accordance with ASTM D1238         at 190° C. and 2.16 kg; and wherein said precursor acid         copolymer, when neutralized to a level of about 40% to about         90%, based on the total number of the carboxylic acid groups         present in the precursor acid copolymer, to comprise carboxylate         groups and counterions that consist essentially of sodium ions,         produces a sodium ionomer, said sodium ionomer having a freeze         enthalpy that is not detectable or that is less than about 3.0         j/g, when determined by differential scanning calorimetry in         accordance with ASTM D3418; and wherein said sodium/zinc mixed         ionomer comprises carboxylate groups and a mixture of         counterions; said mixture of counterions consisting essentially         of about 5 to about 95 equivalent % of sodium cations, and,         complementarily, about 95 to 5 equivalent % of zinc cations,         based on the total number of equivalents of carboxylate groups         in the precursor acid copolymer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view, not-to-scale, of a wafer-based solar cell module disclosed herein.

FIG. 2 is a cross-sectional view, not-to-scale, of one particular thin film solar cell module disclosed herein.

FIG. 3 is a cross-sectional view, not-to-scale, of another thin film solar cell module disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION

The following definitions apply to the terms as used throughout this specification, unless otherwise limited in specific instances.

The technical and scientific terms used herein have the meanings that are commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including the definitions herein, will control.

The term “a finite amount”, as used herein, refers to an amount that is greater than zero.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “containing,” “characterized by,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

The transitional phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term “consisting essentially of”.

When a composition, a process, a structure, or a portion of a composition, a process, or a structure, is described herein using an open-ended term such as “comprising,” unless otherwise stated the description also includes an embodiment that “consists essentially of” the elements of the composition, the process, the structure, or the portion of the composition, the process, or the structure.

The articles “a” and “an” may be employed in connection with various elements and components of compositions, processes or structures described herein. This is merely for convenience and to give a general sense of the compositions, processes or structures. Such a description includes “one or at least one” of the elements or components. Moreover, as used herein, the singular articles also include a description of a plurality of elements or components, unless it is apparent from a specific context that the plural is excluded.

The term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such.

The term “or”, as used herein, is inclusive; that is, the phrase “A or B” means “A, B, or both A and B”. More specifically, a condition “A or B” is satisfied by any one of the following: A is true (or present) and B is false (or not present); A is false (or not present) and B is true (or present); or both A and B are true (or present). Exclusive “or” is designated herein by terms such as “either A or B” and “one of A or B”, for example.

In addition, the ranges set forth herein include their endpoints unless expressly stated otherwise. Further, when an amount, concentration, or other value or parameter is given as a range, one or more preferred ranges or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether such pairs are separately disclosed. The scope of the invention is not limited to the specific values recited when defining a range.

When materials, methods, or machinery are described herein with the term “known to those of skill in the art”, “conventional” or a synonymous word or phrase, the term signifies that materials, methods, and machinery that are conventional at the time of filing the present application are encompassed by this description. Also encompassed are materials, methods, and machinery that are not presently conventional, but that will have become recognized in the art as suitable for a similar purpose.

Unless stated otherwise, all percentages, parts, ratios, and like amounts, are defined by weight.

As used herein, the term “copolymer” refers to polymers comprising copolymerized units resulting from copolymerization of two or more comonomers. In this connection, a copolymer may be described herein with reference to its constituent comonomers or to the amounts of its constituent comonomers, for example “a copolymer comprising ethylene and 15 weight % of acrylic acid”, or a similar description. Such a description may be considered informal in that it does not refer to the comonomers as copolymerized units; in that it does not include a conventional nomenclature for the copolymer, for example International Union of Pure and Applied Chemistry (IUPAC) nomenclature; in that it does not use product-by-process terminology; or for another reason. As used herein, however, a description of a copolymer with reference to its constituent comonomers or to the amounts of its constituent comonomers means that the copolymer contains copolymerized units (in the specified amounts when specified) of the specified comonomers. It follows as a corollary that a copolymer is not the product of a reaction mixture containing given comonomers in given amounts, unless expressly stated in limited circumstances to be such.

The term “dipolymer” refers to polymers consisting essentially of two monomers, and the term “terpolymer” refers to polymers consisting essentially of three monomers.

The term “acid copolymer” as used herein refers to a polymer comprising copolymerized units of an α-olefin, an α,β-ethylenically unsaturated carboxylic acid, and optionally other suitable comonomer(s) such as, an α,β-ethylenically unsaturated carboxylic acid ester.

The term “ionomer” as used herein refers to a polymer that comprises ionic groups that are metal ion carboxylates, for example, alkali metal carboxylates, alkaline earth carboxylates, transition metal carboxylates and/or mixtures of such carboxylates. Such polymers are generally produced by partially or fully neutralizing the carboxylic acid groups of precursor or parent polymers that are acid copolymers, as defined herein, for example by reaction with a base. An example of an alkali metal ionomer is a sodium/zinc mixed ionomer (or sodium/zinc neutralized ionomer), for example a copolymer of ethylene and methacrylic acid wherein all or a portion of the carboxylic acid groups of the copolymerized methacrylic acid units are in the form of zinc carboxylates and sodium carboxylates.

Provided herein is a solar cell module comprising (A) at least one sheet layer comprising at least one layer that comprises or is produced from a sodium/zinc mixed ionomer composition and (B) a solar cell layer comprising one or a plurality of solar cells. The sheet layer functions as an encapsulant layer in the solar cell module. That is, the solar cell modules of the present invention are characterized by having an encapsulant layer having at least one layer of the sodium/zinc mixed ionomer composition.

The sodium/zinc mixed ionomer composition comprises a sodium/zinc mixed ionomer that is an ionic, neutralized derivative of a precursor acid copolymer. The precursor acid copolymer comprises copolymerized units of an α-olefin having 2 to 10 carbons and about 20 to about 30 wt %, or about 20 to about 25 wt %, of copolymerized units of an α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms, based on the total weight of the precursor acid copolymer.

Suitable α-olefin comonomers include, but are not limited to, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 3 methyl-1-butene, 4-methyl-1-pentene, and the like and mixtures of two or more of these α-olefins. In one embodiment, the α-olefin is ethylene.

Suitable α,β-ethylenically unsaturated carboxylic acid comonomers include, but are not limited to, acrylic acids, methacrylic acids, itaconic acids, maleic acids, maleic anhydrides, fumaric acids, monomethyl maleic acids, and mixtures of two or more of these acid comonomers. In one embodiment, the α,β-ethylenically unsaturated carboxylic acid is selected from acrylic acids, methacrylic acids, and mixtures of two or more thereof.

The precursor acid copolymers may further comprise copolymerized units of other comonomer(s), such as unsaturated carboxylic acids having 2 to 10, or 3 to 8 carbon atoms, or derivatives thereof. Suitable acid derivatives include acid anhydrides, amides, and esters. In one embodiment, the precursor acid copolymer further comprises an ester of the unsaturated carboxylic acid. Exemplary esters of unsaturated carboxylic acids include, but are not limited to, methyl acrylates, methyl methacrylates, ethyl acrylates, ethyl methacrylates, propyl acrylates, propyl methacrylates, isopropyl acrylates, isopropyl methacrylates, butyl acrylates, butyl methacrylates, isobutyl acrylates, isobutyl methacrylates, tert-butyl acrylates, tert-butyl methacrylates, octyl acrylates, octyl methacrylates, undecyl acrylates, undecyl methacrylates, octadecyl acrylates, octadecyl methacrylates, dodecyl acrylates, dodecyl methacrylates, 2-ethylhexyl acrylates, 2-ethylhexyl methacrylates, isobornyl acrylates, isobornyl methacrylates, lauryl acrylates, lauryl methacrylates, 2-hydroxyethyl acrylates, 2-hydroxyethyl methacrylates, glycidyl acrylates, glycidyl methacrylates, poly(ethylene glycol)acrylates, poly(ethylene glycol)methacrylates, poly(ethylene glycol) methyl ether acrylates, poly(ethylene glycol) methyl ether methacrylates, poly(ethylene glycol) behenyl ether acrylates, poly(ethylene glycol) behenyl ether methacrylates, poly(ethylene glycol) 4-nonylphenyl ether acrylates, poly(ethylene glycol) 4-nonylphenyl ether methacrylates, poly(ethylene glycol) phenyl ether acrylates, poly(ethylene glycol) phenyl ether methacrylates, dimethyl maleates, diethyl maleates, dibutyl maleates, dimethyl fumarates, diethyl fumarates, dibutyl fumarates, vinyl acetates, vinyl propionates, and mixtures of two or more thereof. Exemplary comonomers that may be comprised in the precursor acid copolymers include, but are not limited to, methyl acrylates, methyl methacrylates, butyl acrylates, butyl methacrylates, glycidyl methacrylates, vinyl acetates, and mixtures of two or more thereof. In one embodiment, the precursor acid copolymer does not incorporate other comonomers in any significant amount.

Mixtures of precursor acid copolymers are also suitable, provided that the properties of the copolymers are within the ranges described herein. For example, two or more dipolymers having differing amounts of copolymerized carboxylic acid comonomer or differing melt flow rates may be used. Also, a mixture of precursor acid copolymers including a dipolymer and a terpolymer may be suitable.

The precursor acid copolymers may be synthesized in a continuous process in which each of the reactive comonomers and the solvent(s), if any, are continuously fed, together with initiator, into a stirred reactor. The choice of initiator is based on the anticipated reactor temperature range coupled with the decomposition temperature of the initiator, the criteria for this selection being well-understood in the industry. In general, during the synthesis by copolymerization of ethylene and acid comonomers to produce the precursor acid copolymer, the reaction temperature may be maintained at about 120° C. to about 300° C., or about 140° C. to about 260° C. The pressure in the reactor may be maintained at about 130 to about 310 MPa, or about 165 to 250 MPa.

The reactor may be, for example, an autoclave such as those disclosed in U.S. Pat. No. 2,897,183. Specifically, U.S. Pat. No. 2,897,183 describes a type of autoclave that is equipped with means for intensive agitation. It also describes a continuous process for the polymerization of ethylene under a “substantially constant environment.” This environment is maintained by keeping certain parameters for example, pressure, temperature, initiator concentration and the ratio of polymer product to unreacted ethylene, substantially constant during the polymerization reaction. Such conditions may be achieved in any of a variety of continuously stirred tank reactors, among them, for example, continuously stirred isothermal reactors and continuously stirred adiabatic reactors.

The reaction mixture, which contains the ethylene copolymer product, is vigorously agitated and continuously removed from the autoclave. After the reaction mixture leaves the reaction vessel, the resulting ethylene copolymer product is separated from the volatile unreacted monomers and solvents, if any, by conventional procedures, such as by vaporizing the unpolymerized materials and solvents under reduced pressure or at an elevated temperature.

In general, to obtain the sodium/zinc mixed ionomers described herein, during the polymerization reaction, the reactor contents should be maintained under conditions such that a single phase is present substantially throughout the reactor. This can be accomplished by adjusting reactor temperature, by adjusting reactor pressure, by addition of co-solvents, or any combination thereof, as disclosed in U.S. Pat. No. 5,028,674. Any conventional means may be used to determine whether a single phase is maintained substantially throughout the reactor. For example, Hasch et al. in “High-Pressure Phase Behavior of Mixtures of Poly(Ethylene-co-Methyl Acrylate) with Low-Molecular Weight Hydrocarbons”, Journal of Polymer Science: Part B: Polymer Physics, Vol. 30, 1365-1373 (1992), describe a cloud-point measurement that can be used in determining the boundary between single-phase and multiphase conditions.

The precursor acid copolymer may have a melt flow rate (MFR) of about 70 to about 1000 g/10 min, or about 100 to about 500 g/10 min, or about 150 to about 300 g/10 min, or about 200 to about 300 g/10 min, as determined in accordance with ASTM method D1238 at 190° C. and 2.16 kg.

It has been found that when such a precursor acid copolymer is neutralized with a sodium ion-containing base to a level of about 40% to about 90%, or about 40% to about 70%, or about 43% to about 60%, based on the total carboxylic acid content of the precursor acid copolymers as calculated or measured for the non-neutralized precursor acid copolymers, the resulting sodium (neutralized) ionomer has a MFR of about 0.7 to about 25 g/10 min or less, or about 0.7 to about 19 g/10 min or less, or about 1 to about 10 g/10 min, or about 1.5 to about 5 g/10 min, or about 2 to about 4 g/10 min, as determined in accordance with ASTM method D1238 at 190° C. and 2.16 kg and that the resulting sodium ionomer has a freeze enthalpy that is not detectable or less than about 3 j/g, or less than about 2 j/g, as determined by differential scanning calorimetry (DSC) in accordance with ASTM method D3418 when using a DSC apparatus manufactured by Mettler or by TA (for example the Universal V3.9A model). By “not detectable”, it is meant there is no observable inflection on the DSC curve. Alternatively, the peak height may be very small and the peak width at half height may be relatively great, so that a broad peak having a small integral area may not be discerned when a baseline is subtracted from the DSC trace. In general, when ASTM D3418 is followed, a freeze enthalpy that falls below 0.2 j/g would not be detectable. Such precursor acid copolymers and the resulting sodium ionomers are disclosed in Applicants' co-pending U.S. Provisional Application 61/110,486 (filed on Oct. 31, 2008).

To obtain the sodium/zinc mixed ionomers described herein, the precursor acid copolymers are neutralized with a mixture of sodium and zinc ion-containing bases to provide an ionomer wherein about 30% to about 90%, or about 40% to about 70%, or about 43% to about 60%, of the hydrogen atoms of carboxylic acid groups of the precursor acid copolymers are replaced by a mixture of zinc and sodium cations (i.e. zinc and sodium counterions). That is, the acid groups are neutralized to a level of about 30% to about 90%, or about 40% to about 70%, or about 43% to about 60%, based on the total carboxylic acid content of the precursor acid copolymers as calculated or measured for the non-neutralized precursor acid copolymers. The mixture of the sodium and zinc cations present in the resulting ionomers is such that the percentage of equivalents of sodium cations and zinc cations may comprise about 5 to about 95 equivalent %, or about 50 to about 95 equivalent %, or about 55 to about 80 equivalent %, or about 55 to about 70 equivalent %, or about 60 to about 70 equivalent %, of sodium cations, with the balance of the equivalent percentage being the zinc cations.

The sodium/zinc mixed ionomer used herein may also be prepared by first neutralizing the precursor acid copolymer with an appropriate amount of a sodium ion-containing base, such as a solution of sodium hydroxide, and then an appropriate amount of a zinc ion-containing base, such as a solution of zinc acetate. The sodium/zinc mixed ionomer used herein may also be prepared by first neutralizing the precursor acid copolymer with an appropriate amount of a zinc ion-containing base, such as a solution of zinc acetate, and then an appropriate amount of a sodium ion-containing base, such as a solution of sodium hydroxide.

The sodium/zinc mixed ionomer used herein may also be prepared by melt blending a sodium neutralized ionomer and a zinc neutralized ionomer, each derived from a precursor acid copolymer as described above, provided that the resulting sodium/zinc mixed ionomer has a total of about 30% to about 90%, or about 40% to about 70%, or about 43% to about 60%, of the hydrogen atoms of the carboxylic acid groups present in the two precursor acid copolymers replaced by metal cations and that, among the metal cations, about 5 to about 95 equivalent %, or about 50 to about 95 equivalent %, or about 55 to about 80 equivalent %, or about 55 to about 70 equivalent %, or about 60 to about 70 equivalent %, are sodium cations, with the balance being zinc cations. In one embodiment, the sodium/zinc mixed ionomer is prepared by melt blending a sodium neutralized ionomer, in which about 30 equivalent % to about 90 equivalent %, or about 40 equivalent % to about 70 equivalent %, or about 43 equivalent % to about 60 equivalent %, of the hydrogen atoms of the carboxylic acid groups present in its precursor acid copolymer are replaced by sodium cations, and a zinc neutralized ionomer, in which about 30 equivalent % to about 90 equivalent %, or about 40 equivalent % to about 70 equivalent %, or about 43 equivalent % to about 60 equivalent %, of the hydrogen atoms of the carboxylic acid groups present in its precursor acid copolymer are replaced by a charge-equivalent amount of zinc cations.

To obtain the sodium neutralized ionomers, the zinc neutralized ionomers, or the sodium/zinc mixed ionomers described herein, the precursor acid copolymers may be neutralized by any conventional procedure, such as those disclosed in U.S. Pat. Nos. 3,404,134 and 6,518,365.

The resulting sodium/zinc neutralized ionomer may have a MFR of about 25 g/10 min or less, or about 0.7 to about 25 g/10 min or less, or about 0.7 to about 19 g/10 min or less, or about 1 to about 10 g/10 min, or about 1.5 to about 5 g/10 min, or about 2 to about 4 g/10 min, as determined in accordance with ASTM method D1238 at 190° C. and 2.16 kg.

The sodium/zinc mixed ionomer composition may further contain other additives known within the art. The additives may include, but are not limited to, processing aids, flow enhancing additives, lubricants, pigments, dyes, flame retardants, impact modifiers, nucleating agents, anti-blocking agents such as silica, thermal stabilizers, UV absorbers, UV stabilizers, dispersants, surfactants, chelating agents, coupling agents, reinforcement additives, such as glass fiber, fillers and the like. Generally, additives that may reduce the optical clarity of the composition, such as reinforcement additives and fillers, are reserved for those sheets that are used as the back encapsulants.

Thermal stabilizers can be used and have been widely disclosed within the art. Any known thermal stabilizer may find utility within the invention. Exemplary general classes of thermal stabilizers include, but are not limited to, phenolic antioxidants, alkylated monophenols, alkylthiomethylphenols, hydroquinones, alkylated hydroquinones, tocopherols, hydroxylated thiodiphenyl ethers, alkylidenebisphenols, O-, N- and S-benzyl compounds, hydroxybenzylated malonates, aromatic hydroxybenzyl compounds, triazine compounds, aminic antioxidants, aryl amines, diaryl amines, polyaryl amines, acylaminophenols, oxamides, metal deactivators, phosphites, phosphonites, benzylphosphonates, ascorbic acid (vitamin C), compounds that destroy peroxide, hydroxylamines, nitrones, thiosynergists, benzofuranones, indolinones, and the like and mixtures thereof. The sodium/zinc mixed ionomer composition may contain any effective amount of thermal stabilizers. Use of a thermal stabilizer is optional. When thermal stabilizers are used, the sodium/zinc mixed ionomer composition may contain at least about 0.05 wt % and up to about 10 wt %, or up to about 5 wt %, or up to about 1 wt %, of thermal stabilizers, based on the total weight of the sodium/zinc mixed ionomer.

UV absorbers can be used and have also been widely disclosed within the art. Any known UV absorber may find utility within the present invention. Exemplary general classes of UV absorbers include, but are not limited to, benzotriazoles, hydroxybenzophenones, hydroxyphenyl triazines, esters of substituted and unsubstituted benzoic acids, and the like and mixtures thereof. The sodium/zinc mixed ionomer composition may contain any effective amount of UV absorbers. Use of a UV absorber is optional. When UV absorbers are utilized, the sodium/zinc mixed ionomer composition may contain at least about 0.05 wt % and up to about 10 wt %, or up to about 5 wt %, or up to about 1 wt %, of UV absorbers, based on the total weight of the sodium/zinc mixed ionomer composition.

Hindered amine light stabilizers (HALS) can be used and have also been widely disclosed within the art. Generally, hindered amine light stabilizers are disclosed to be secondary, tertiary, acetylated, N-hydrocarbyloxy substituted, hydroxy substituted N-hydrocarbyloxy substituted, or other substituted cyclic amines which are characterized by a substantial amount of steric hindrance, generally derived from aliphatic substitution on the carbon atoms adjacent to the amine function. The sodium/zinc mixed ionomer composition may contain any effective amount of hindered amine light stabilizers. Use of hindered amine light stabilizers is optional. When hindered amine light stabilizers are used, the sodium/zinc mixed ionomer composition may contain at least about 0.05 wt % and up to about 10 wt %, or up to about 5 wt %, or up to about 1 wt %, of hindered amine light stabilizers, based on the total weight of the sodium/zinc mixed ionomer composition.

Silane coupling agents may be added to the sodium/zinc mixed ionomer composition to improve its adhesive strength. Exemplary silane coupling agents that are useful in the compositions of the invention include, but are not limited to, γ-chloropropylmethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(β-methoxyethoxy)silane, γ-vinylbenzylpropyltrimethoxysilane, N-β-(N-vinylbenzylaminoethyl)-γ-aminopropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, vinyltrichlorosilane, γ-mercaptopropylmethoxysilane, γ-aminopropyltriethoxysilane, N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane, and mixtures of two or more thereof. The silane coupling agents may be incorporated in the sodium/zinc mixed ionomer composition at a level of about 0.01 to about 5 wt %, or about 0.05 to about 1 wt %, based on the total weight of the sodium/zinc mixed ionomer composition.

As evidenced by the low level of haze and moisture absorption, the polymeric sheets comprising such sodium/zinc mixed ionomers possess higher clarity and moisture resistance, compared to those sheets formed of prior art ionomers. In particular, as illustrated in the example section below, when a polymer sheet with a thickness of 2.28 mm and made of the sodium/zinc mixed ionomer is laminated between two sheets of 3 mm thick annealed glass, the resulting glass laminate has a percent haze level less than about 5% or less than about 3%, independent of the cooling rate that was used during the lamination process. In addition, the polymer sheet made of the sodium/zinc mixed ionomer has a moisture weight gain of less than about 5% or less than about 3% after immersion in water for 1000 hours at 23° C.

The sheet comprising the sodium/zinc mixed ionomer composition and functioning as an encapsulant layer of the solar cell module of the invention may be in a single layer or in multilayer form. By “single layer”, it is meant that the sheet is made of or consists essentially of the sodium/zinc mixed ionomer composition. When in a multilayer form, at least one of the sub-layers is made of or consists essentially of the sodium/zinc mixed ionomer composition, while the other sub-layer(s) may be made of any other suitable polymeric material(s), such as, for example, acid copolymers as previously defined herein, ionomers of acid copolymers as previously defined herein, poly(ethylene vinyl acetates), poly(vinyl acetals) (including acoustic grade poly(vinyl acetals)), polyurethanes, polyvinylchlorides, polyethylenes (e.g., linear low density polyethylenes), polyolefin block copolymer elastomers, copolymers of α-olefins and α,β-ethylenically unsaturated carboxylic acid esters (e.g., ethylene methyl acrylate copolymers and ethylene butyl acrylate copolymers), silicone elastomers, epoxy resins, and combinations of two or more thereof.

Further the sheet comprising the sodium/zinc mixed ionomer composition may have a total thickness of about 1 to about 120 mils (about 0.025 to about 3 mm), or about 5 to about 100 mils (about 0.127 to about 2.54 mm), or about 5 to about 45 mils (about 0.127 to about 1.14 mm), or about 10 to about 30 mils (about 0.25 to about 0.76 mm), or about 10 to about 20 mils (about 0.25 to about 0.51 mm).

The sheet comprising the sodium/zinc mixed ionomer composition may have a smooth or rough surface on one or both sides. In one embodiment, the sheet has rough surfaces on both sides to facilitate deaeration during the lamination process. Rough surfaces can be created by mechanical embossing or by melt fracture during extrusion of the sheets followed by quenching so that surface roughness is retained during handling. The surface pattern can be applied to the sheet through common art processes. For example, the as-extruded sheet may be passed over a specially prepared surface of a die roll positioned in close proximity to the exit of the die which imparts the desired surface characteristics to one side of the molten polymer. Thus, when the surface of such a die roll has minute peaks and valleys, the polymer sheet cast thereon will have a rough surface on the side that is in contact with the roll, and the rough surface generally conforms respectively to the valleys and peaks of the roll surface. Such die rolls are disclosed in, e.g., U.S. Pat. No. 4,035,549 and U.S. Patent Publication No. 2003/0124296.

The sheets comprising the sodium/zinc mixed ionomer composition can be produced by any suitable process. For example, the sheets may be formed through dipcoating, solution casting, compression molding, injection molding, lamination, melt extrusion casting, blown film, extrusion coating, tandem extrusion coating, or by any other procedures that are known to those of skill in the art. In certain embodiments, the sheets may be formed by melt extrusion casting, melt coextrusion casting, melt extrusion coating, or tandem melt extrusion coating processes.

The term “solar cell” is meant to include any article which can convert light into electrical energy. Solar cells useful in the invention include, but are not limited to, wafer-based solar cells (e.g., c-Si or mc-Si based solar cells, as described above in the background section) and thin film solar cells (e.g., a-Si, μc-Si, CdTe, CIS, CIGS, light absorbing dyes, or organic semiconductors based solar cells, as described above in the background section). Within the solar cell layer, the solar cells may be electrically interconnected and/or arranged in a flat plane. In addition, the solar cell layer may further comprise electrical wirings, such as cross ribbons and bus bars.

The solar cell layer may be bifacial. In such an embodiment, all the laminating materials positioned on either side of the solar cell layer should be sufficiently transparent to allow sunlight or reflected sunlight to reach the solar cells. Or, the solar cell layer may have a front sun-facing side (which is also referred to as a front side and, when in actual use conditions, would generally face toward the sun) and a back non-sun-facing side (which is also referred to as a back side and, when in actual use conditions, would generally face away from the sun). In such an embodiment, all the materials that are present in the laminate layers and sub-layers positioned to the front sun-facing side of the solar cell layer should have sufficient transparency to allow the sunlight to reach the solar cells. The laminating materials present in the laminate layers and sub-layers positioned to the back non-sun-facing side of the solar cell layer need not be transparent.

The solar cell module disclosed herein typically comprises at least one encapsulant sheet comprising the sodium/zinc mixed ionomer composition, which is laminated to the solar cell layer. By “laminated”, it is meant that, within a laminated structure, the two layers are bonded either directly (i.e., without any additional material between the two layers) or indirectly (i.e., with additional material, such as interlayer or adhesive materials, between the two layers). In one embodiment, the encapsulant sheet comprising the sodium/zinc mixed ionomer composition is directly bonded to the solar cell layer.

The solar cell module may further comprise additional encapsulant layers comprising other polymeric materials, such as acid copolymers, ionomers of acid copolymers, ethylene/vinyl acetate copolymers, poly(vinyl acetals) (including acoustic grade poly(vinyl acetals)), polyurethanes, poly(vinyl chlorides), polyethylenes (e.g., linear low density polyethylenes), polyolefin block copolymer elastomers, copolymers of α-olefins and α,β-ethylenically unsaturated carboxylic acid esters) (e.g., ethylene methyl acrylate copolymers and ethylene butyl acrylate copolymers), silicone elastomers, epoxy resins, and combinations of two or more thereof.

The thickness of each of the encapsulant layers other than the sheet comprising the sodium/zinc mixed ionomer composition may independently range from about 1 to about 120 mils (about 0.025 to about 3 mm), or about 5 to about 100 mils (about 0.127 to about 2.54 mm), or about 5 to about 45 mils (about 0.127 to about 1.14 mm), or about 10 to about 30 mils (about 0.25 to about 0.76 mm), or about 10 to about 20 mils (about 0.25 to about 0.51 mm). Any or all of the encapsulant layer(s) comprised in the solar cell modules including the sheet comprising the sodium/zinc mixed ionomer composition, may have smooth or rough surfaces.

The solar cell module may further comprise an incident layer and/or a backing layer serving as the outermost layer or layers of the module at the sun-facing side and the non-sun-facing side of the solar cell module, respectively.

The outer layers of the solar cell modules, i.e., the incident layer and the backing layer, may be derived from any suitable sheets or films. Suitable sheets may be glass or plastic sheets, such as polycarbonates, acrylics, polyacrylates, cyclic polyolefins (e.g., ethylene norbornene polymers), polystyrenes (preferably polystyrenes prepared in the presence of metallocene catalysts), polyamides, polyesters, fluoropolymers, or combinations of two or more thereof. In addition, metal sheets, such as aluminum, steel, galvanized steel, or ceramic plates may be utilized in forming the backing layer.

The term “glass” includes not only window glass, plate glass, silicate glass, sheet glass, low iron glass, tempered glass, tempered CeO-free glass, and float glass, but also colored glass, specialty glass (such as those containing ingredients to control solar heating), coated glass (such as those sputtered with metals (e.g., silver or indium tin oxide) for solar control purposes), low E-glass, Toroglas® glass (Saint-Gobain N.A. Inc., Trumbauersville, Pa.), Solexia™ glass (PPG Industries, Pittsburgh, Pa.) and Starphire® glass (PPG Industries). Such specialty glasses are disclosed in, e.g., U.S. Pat. Nos. 4,615,989; 5,173,212; 5,264,286; 6,150,028; 6,340,646; 6,461,736; and 6,468,934. It is understood, however, that the type of glass to be selected for a particular module depends on the intended use.

Suitable film layers comprise polymers that include but are not limited to, polyesters (e.g., poly(ethylene terephthalate) and poly(ethylene naphthalate)), polycarbonates, polyolefins (e.g., polypropylene, polyethylene, and cyclic polyolefins), norbornene polymers, polystyrenes (e.g., syndiotactic polystyrene), styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones (e.g., polyethersulfone, polysulfone, etc.), nylons, polyurethanes, acrylics, cellulose acetates (e.g., cellulose acetate, cellulose triacetates, etc.), cellophanes, silicones, poly(vinyl chlorides) (e.g., poly(vinylidene chloride)), fluoropolymers (e.g., polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymers, etc.), and combinations of two or more thereof. The polymeric film may be non-oriented, or uniaxially oriented, or biaxially oriented. Some specific exemplary films that may be used in the solar cell module outer layers (e.g., the incident layer or the backing layer) include, but are not limited to, polyester films (e.g., poly(ethylene terephthalate) films), fluoropolymer films (e.g., Tedlar®, Tefzel®, and Teflon® films available from E. I. du Pont de Nemours and Company (DuPont), Wilmington, Del.). Metal films, such as aluminum foil, may also be used as the backing layers. Further the films used in the solar cell module outer layers may be in the form of multi-layer films, such as a fluoropolymer/polyester/fluoropolymer multilayer film (e.g., Tedlar®/PET/Tedlar® or TPT laminate film available from Isovolta AG., Austria or Madico, Woburn, Mass.).

The solar cell module may further comprise other functional film or sheet layers (e.g., dielectric layers or barrier layers) embedded within the module. Such functional layers may be derived from any of the above mentioned polymeric films or those that are coated with additional functional coatings. For example, poly(ethylene terephthalate) films coated with a metal oxide coating, such as those disclosed in U.S. Pat. Nos. 6,521,825 and 6,818,819 and European Patent No. EP1182710, may function as oxygen and moisture barrier layers in the laminates.

If desired, a layer of nonwoven glass fiber (scrim) may also be included between the solar cell layers and the encapsulants to facilitate deaeration during the lamination process and/or to serve as reinforcement for the encapsulants. The use of such scrim layers is disclosed within, e.g., U.S. Pat. Nos. 5,583,057; 6,075,202; 6,204,443; 6,320,115; and 6,323,416 and European Patent No. EP0769818.

A special film or sheet may be included to serve both the function of an encapsulant layer and an outer layer. It is also conceivable that any of the film or sheet layers included in the module may be in the form of a pre-formed single-layer or multilayer film or sheet.

If desired, one or both surfaces of the incident layer films and sheets, the backing layer films and sheets, the encapsulant layers and other layers incorporated within the solar cell module may undergo any suitable adhesion enhancing treatment. This adhesion enhancing treatment may take any form known within the art and includes flame treatments (see, e.g., U.S. Pat. Nos. 2,632,921; 2,648,097; 2,683,894; and 2,704,382), plasma treatments (see e.g., U.S. Pat. No. 4,732,814), electron beam treatments, oxidation treatments, corona discharge treatments, chemical treatments, chromic acid treatments, hot air treatments, ozone treatments, ultraviolet light treatments, sand blast treatments, solvent treatments, and combinations of two or more thereof. Also, the adhesion strength may be further improved by further applying an adhesive or primer coating on the surface of the laminate layer(s). For example, U.S. Pat. No. 4,865,711 discloses a film or sheet with improved bondability, which has a thin layer of carbon deposited on one or both surfaces. Other exemplary adhesives or primers may include silanes, poly(allyl amine) based primers (see e.g., U.S. Pat. Nos. 5,411,845; 5,770,312; 5,690,994; and 5,698,329), and acrylic based primers (see e.g., U.S. Pat. No. 5,415,942). The adhesive or primer coating may take the form of a monolayer of the adhesive or primer and have a thickness of about 0.0004 to about 1 mil (about 0.00001 to about 0.03 mm), or about 0.004 to about 0.5 mil (about 0.0001 to about 0.013 mm), or about 0.004 to about 0.1 mil (about 0.0001 to about 0.003 mm).

In one embodiment (now referring to FIG. 1), where the solar cells are derived from wafer-based self supporting solar cell units, the solar cell module (20) may comprise, in order of position from the front sun-facing side to the back non-sun-facing side, (a) an incident layer (10), (b) a front encapsulant layer (12), (c) a solar cell layer (14) comprised of one or more electrically interconnected solar cells, (d) a back encapsulant layer (16), and (e) a backing layer (18), wherein at least one or both of the front and back encapsulant layers (12 and 16) is formed of the sheet comprising the sodium/zinc mixed ionomer composition.

In a further embodiment, the solar cell modules are derived from thin film solar cells and may (i) in one embodiment (30 in FIG. 2), comprise, in order of position from the front sun-facing side to the back non-sun-facing side, (a) a solar cell layer (14 a) comprising a superstrate (24) and a layer of thin film solar cell(s) (22) deposited thereon at the non-sun-facing side, (b) a (back) encapsulant layer (16) formed of the sheet comprising the sodium/zinc mixed ionomer composition, and (c) a backing layer (18) or (ii) in another embodiment (40 in FIG. 3), comprise, (a) a transparent incident layer (10), (b) a (front) encapsulant layer (12) formed of the sheet comprising the sodium/zinc mixed ionomer composition, and (c) a solar cell layer (14 b) comprising a layer of thin film solar cell(s)(22) deposited on a substrate (26) at the sun-facing side thereof.

Moreover, a series of the solar cell modules described above may be further linked to form a solar cell array, which can produce a desired voltage and current.

Any lamination process known within the art (such as an autoclave process or a non-autoclave process) may be used to prepare the solar cell modules.

In an exemplary process, the component layers of the solar cell module are stacked in the desired order to form a pre-lamination assembly. The assembly is then placed into a bag capable of sustaining a vacuum (“a vacuum bag”), the air is drawn out of the bag by a vacuum line or other means, the bag is sealed while the vacuum is maintained (e.g., at least about 27-28 in Hg (689-711 mm Hg)), and the sealed bag is placed in an autoclave and the pressure is raised to about 150 to about 250 psi (about 11.3 to about 18.8 bar), a temperature of about 130° C. to about 180° C., or about 130° C. to about 160° C., or about 135° C. to about 155° C., or about 145° C. to about 155° C., for about 10 to about 50 min, or about 20 to about 45 min, or about 20 to about 40 min, or about 25 to about 35 min. A vacuum ring may be substituted for the vacuum bag. One type of suitable vacuum bag is disclosed within U.S. Pat. No. 3,311,517. Following the heat and pressure cycle, the air in the autoclave is cooled without adding additional gas to maintain pressure in the autoclave. After about 20 min of cooling, the excess air pressure is vented and the laminates are removed from the autoclave.

Alternatively, the pre-lamination assembly may be heated in an oven at about 80° C. to about 120° C., or about 90° C. to about 100° C., for about 20 to about 40 min, and thereafter, the heated assembly is passed through a set of nip rolls so that the air in the void spaces between the individual layers may be squeezed out, and the edge of the assembly sealed. The assembly at this stage is referred to as a pre-press.

The pre-press may then be placed in an air autoclave where the temperature is raised to about 120° C. to about 160° C., or about 135° C. to about 160° C., at a pressure of about 100 to about 300 psi (about 6.9 to about 20.7 bar), or preferably about 200 psi (13.8 bar). These conditions are maintained for about 15 to about 60 min, or about 20 to about 50 min, after which the air is cooled while no further air is introduced to the autoclave. After about 20 to about 40 min of cooling, the excess air pressure is vented and the laminated products are removed from the autoclave.

The solar cell modules may also be produced through non-autoclave processes. Such non-autoclave processes are disclosed, e.g., in U.S. Pat. Nos. 3,234,062; 3,852,136; 4,341,576; 4,385,951; 4,398,979; 5,536,347; 5,853,516; 6,342,116; and 5,415,909, U.S. Patent Publication No. 2004/0182493, European Patent No. EP1235683 B1, and PCT Patent Publication Nos. WO91/01880 and WO03/057478. Generally, the non-autoclave processes include heating the pre-lamination assembly and the application of vacuum, pressure or both. For example, the assembly may be successively passed through heating ovens and nip rolls.

These examples of lamination processes are not intended to be limiting. Essentially any lamination process may be used.

If desired, the edges of the solar cell module may be sealed to reduce moisture and air intrusion that lead to potential reduction of the efficiency and lifetime of the solar cell(s). The edges may be sealed by any means disclosed within the art. Suitable edge seal materials include, but are not limited to, butyl rubber, polysulfide, silicone, polyurethane, polypropylene elastomers, polystyrene elastomers, block copolymer elastomers, styrene-ethylene-butylene-styrene (SEBS), and the like.

The invention is further illustrated by the following examples of certain embodiments.

EXAMPLES

The following Examples are intended to be illustrative of the invention, and are not intended in any way to limit the scope of the invention.

Comparative Examples CE1-CE19

The ionomers used in each of the following examples were prepared as follows. First, the precursor acid copolymers (i.e., the copolymers of ethylene and methacrylic acid) of the ionomers were produced by free radical polymerization in an adiabatic continuous stirred autoclave, substantially according to the procedure described in Example 1 of U.S. Pat. No. 5,028,674 with the following exceptions: (1) by controlling the ratio of ethylene to methacrylic acid and the flow rate of the initiator, the reactor conditions were maintained at a temperature of about 200° C. to about 260° C. and at a pressure of between 170 and 240 MPa; (2) no propane telogen was fed in the reactor (except in CE16); (3) the total concentration of methanol in the reactor was maintained at about 2 to 5 mol %, based on the total feed of ethylene, methacrylic acid, methanol and initiator solution (or based on the total feed of propane telogen, ethylene, methacrylic acid, methanol, and initiator solution in CE16); and (4) the system was maintained at a steady state with the residence time of the material flowing through the reactor being about 5 seconds to 2 minutes. In addition, depending on the particular acid copolymer to be synthesized, one of two different free-radical initiators were used, tert-butyl peracetate or tert-butyl peroctoate. When tert-butyl peracetate was the initiator (as in CE1-CE6, CE16, and CE18), it was utilized as a solution in odorless mineral spirits at 50% concentration. When tert-butyl peroctoate was the initiator (as in CE7-CE15, CE17, and CE19), it was utilized as a mixture at 90% concentration in odorless mineral spirits. Then the ionomers were obtained by partially neutralizing the precursor copolymers of ethylene and methacrylic acid with sodium hydroxide solution either in a single screw extruder under high shear melt mixing conditions with the melt temperature set at 200° C. to 270° C., or using the general method described in Example 1 of U.S. Pat. No. 6,518,365.

The ionomers thus obtained then underwent differential scanning calorimetry (DSC) testing in accordance with ASTM D3418 with a temperature profile of (a) heating to 180° C.; (b) holding for 3 minutes; (c) cooling to 25° C. at a rate of 10° C./min; (d) holding for 3 minutes; and (e) heating to 180° C. at a rate of 10° C./min. The freeze enthalpies for the ionomers were determined and are reported in Table 2. The results demonstrate that a freeze enthalpy for each of the sodium ionomers prepared by neutralizing the disclosed precursor acid copolymers using sodium ion-containing bases (CE1-CE3) was not detectable, while each of the ionomers prepared by neutralizing the prior art precursor acid copolymers (CE4-CE19) has a freeze enthalpy greater than 3 j/g.

Further, the ionomers were fed into 25 mm diameter Killion extruders under the temperature profile set in Table 1 and extrusion cast into polymer sheets. Specifically, the polymer throughput was controlled by adjusting the screw speed to maximum throughput, a 150 mm slot die with a nominal gap of 2 mm was fed by the extruder, the cast sheet was fed onto a 200 mm diameter polished chrome chill roll held at a temperature of between 10° C. and 15° C. and rotating at 1 to 2 rpm. The nominally 0.76 mm (30 mil) thick sheets were then removed and cut into 300×300 mm squares.

The ionomer sheets were used as interlayer sheets to form glass laminates. Specifically, annealed glass sheets (100×100×3 mm) were washed with a solution of trisodium phosphate (5 g/l) in de-ionized water at 50° C. for 5 min, then rinsed thoroughly with de-ionized water and dried. Six layers of each respective ionomer sheet (about 0.76 mm thick each) were stacked together and placed between the two lites of glass sheet (to yield an interlayer thickness of 180 mils (4.57 mm)). The moisture level of the ionomer sheets was kept below 0.06% by weight by minimizing contact time with the room environment (˜35% RH). The pre-lamination assembly was then taped together with a piece of polyester tape in several locations to maintain relative positioning of each layer with the glass lites. A nylon fabric strip was placed around the periphery of the assembly to facilitate air removal from within the layers. The assembly was placed inside a nylon vacuum bag, sealed and then a connection was made to a vacuum pump. Vacuum was applied to allow substantial removal of air from within the bagged assembly (air pressure inside the bag was reduced to below 50 millibar absolute). The bagged assembly was then heated in a convection air oven to 120° C. and maintained at these conditions for 30 min. A cooling fan was then used to cool the assembly to near ambient temperature, after which the vacuum source was disconnected and the bag was removed, yielding a fully pre-pressed assembly of glass and interlayer. Although hermetically sealed around the periphery, several areas of the assembly were not fully bonded as indicated by the presence of bubbles in these areas. The assembly was then placed in an air autoclave and the temperature and pressure were increased from ambient to 135° C. at 13.8 bar over 15 min. The assembly was maintained at such condition for 30 min, after which, the resulting laminate was rapidly cooled (i.e., at Cooling Condition A of 2.5° C./min) to room temperature at ambient pressure. The thus obtained laminate was then tested for haze in accordance with ASTM D1003 using a Haze-gard Plus hazemeter (BYK-Gardner, Columbia, Md.). Thereafter, the same laminate was heated to 120° C. in an oven and maintained at such temperature for 2 to 3 hours before it was slowly cooled (i.e., Cooling Condition B of 0.1° C./min) to room temperature and then tested for haze.

As shown by the comparative examples (CE4-CE19), the haze levels of glass laminates comprising interlayer ionomers prepared by neutralizing prior art precursor acid copolymers are dependent on the cooling rate under which the laminates were obtained. In general, a slower cooling rate would increase the laminate haze and therefore decrease the optical property thereof. However, as illustrated by the data shown in Table 2, glass laminates comprising interlayer ionomers prepared by neutralizing the hereabove disclosed acid copolymers with sodium ion-containing bases (CE1-CE3) tend to exhibit lower haze than glass laminates comprising interlayer ionomers prepared by neutralizing the prior art precursor acid copolymers (CE4-CE19). Additionally, the haze levels of the glass laminates in CE1-CE3 were not affected by the cooling rate under which the laminates were obtained.

TABLE 1 Extruder Zone Temperature (° C.) Feed Ambient Zone 1 100-170 Zone 2 150-210 Zone 3 170-230 Adapter 170-230 Die 170-230

TABLE 2 Freeze Laminate Haze Single MAA MFR % Neut. MFR Enthalpy Cooling Cooling Example Phase¹ (wt %)² (Base Resin)³ (Sodium)⁴ (Ionomer)⁵ (j/g) Condition A Condition B CE1 Yes 23 270 43 3.2 n.d.⁶ 0.7 1.1 CE2 Yes 23 270 52 0.8 n.d.⁶ 1.2 1.4 CE3 Yes 22 350 53 2.5 n.d.⁶ 0.6 0.6 CE4 Yes 23 270 33 8.2 3.13 0.9 9.8 CE5 Yes 23 270 26 16.0 7.32 5.3 21.6 CE6 Yes 23 270 14 40.0 21.97 5.1 59.1 CE7 No 22 25 38 0.4 4.38 1.2 8.6 CE8 No 22 25 30 0.9 13.36 3.4 11.9 CE9 No 22 25 25 1.5 16.31 3.8 17.2 CE10 No 22 25 20 2.3 20.95 3.2 23.5 CE11 No 22 25 15 3.4 27.15 2.5 33.5 CE12 No 22 30 32 1.2 10.18 1.9 10.8 CE13 No 22 30 32 1.2 16.09 2.6 14.4 CE14 No 22 25 26 1.8 14.22 1.8 18.7 CE15 No 21 30 29 2.0 21.67 1.5 21.2 CE16 No 20 350 49 3.2 4.4 1.1 12.5 CE17 No 20 12 23 0.5 25.47 2.6 26.7 CE18 No 19 225 45 4.5 10.81 3.1 27.5 CE19 No 19 60 37 2.6 18.20 1.5 50.8 ¹During the polymerization process, a single phase was maintained throughout the reactor; ²Weight percent of copolymerized units of methacrylic acid comprised in the precursor acid copolymer, from which the ionomer that forms the laminate interlayer sheet is derived; ³The melt flow rate (MFR) of the precursor acid copolymer was calculated based on the MFR of the ionomer; ⁴% neut. Sodium is the percentage of carboxylic acid groups present in the precursor acid copolymer which have been neutralized; ⁵The melt flow rate (MFR) of the ionomer, as determined in accordance with ASTM D1238 at 190° C. and 2.16 kg; ⁶“n.d.” means that the freeze enthalpy is not detectable, when measured in accordance with ASTM D3418-03.

Examples E1-E7 and Comparative Examples CE20-CE24

The ionomers used in CE20-CE24 were prepared in substantially the same manner as disclosed above for CE1-CE19, except that a solution of zinc acetate or zinc oxide concentrate was used instead of the solution of sodium hydroxide in preparing the ionomers used in CE22 and CE23. In preparing the ionomers used in E1-E3, a process similar to that used in CE1-CE19 was conducted, except that the precursor acid copolymer was first neutralized by injecting an appropriate amount of sodium hydroxide solution and then injecting an appropriate amount of zinc acetate solution. The ionomer used in E4 was prepared by melt blending 75 wt % of the ionomer used in CE21 and 25 wt % of the ionomer used in CE22. The ionomer used in E5 was prepared by melt blending 50 wt % of the ionomer used in CE21 and 50 wt % of the ionomer used in CE22. The ionomer used in E6 was prepared by melt blending 25 wt % of the ionomer used in CE21 and 75 wt % of the ionomer used in CE22. The ionomer used in E7 was prepared by melt blending 50 wt % of the ionomer used in CE22 and 50 wt % of the ionomer used in CE24.

Using an extrusion process similar to those described above, the ionomer resins used in E1-E7 and CE20-CE24 were formed into nominally 30 mil (0.76 mm) or 33 mil (0.84 mm) thick sheets and cut into 300×300 mm squares.

The ionomer sheets in each example (100×50×0.76 mm) were weighed and then immersed in water at 23° C. for 1000 hours. After removal from the water, the sheets were blotted to remove residual surface moisture and then re-weighed. The difference in weight before and after water immersion divided by the sheet weight before water immersion was calculated as the moisture weight gain percent (%), which is summarized in Table 3.

Using a lamination process similar to those described above, a second set of ionomer sheets was laminated between two annealed glass sheets (100×100×3 mm) to form glass laminates and the percent haze of each laminate was determined under the conditions of Cooling Condition A or Cooling Condition B. Results are shown in Table 3. In some examples (CE21, CE22, CE24, and E4-E7), after the lamination process was complete, the laminates were further processed using a protocol referred to herein as “Cooling Condition C”. This protocol consists of 1) heating a laminate in an air oven by raising the temperature from ambient temperature to 70° C. over a period of 9 minutes, 2) maintaining a temperature of 70° C. for 15 minutes, 3) raising the temperature to 125° C. over a period of 55 minutes, 4) maintaining the temperature at 125° C. for 15 minutes, 5) cooling from 125° C. to 90° C. over a period of 7 minutes, 6) maintaining a temperature of 90° C. for 15 minutes, and 7) cooling from 90° C. to 25° C. over a period of 10 hours and 50 minutes. The thus-obtained laminates were then tested for percent haze. Results are shown in Table 3.

The results reported in Table 3, demonstrate that in general, laminated sheets of zinc ionomers (CE22 and CE23) tend to exhibit poorer optical properties than laminated sheets of sodium ionomers (CE20, CE21, and CE24). The inclusion of zinc cations improves the moisture resistance of the resulting sodium/zinc ionomer sheets compared to that of sheets of sodium ionomers. Additionally, the inclusion of the zinc cations has no or very minimal effects on the optical properties (as shown by the lower haze levels) of the resulting mixed ionomers, especially at higher sodium/zinc cation ratios.

TABLE 3 MFR Freeze (g/10 min) % Neut MFR Haze (%) Moisture MAA Enthalpy (Base (Na:Zn mole (g/10 min) Cooling Cooling Cooling Gain Sample (wt %) (j/g) Resin) ration) (ionomer) Rate A Rate B Rate C (wt %) CE20 19 17.3  60 39   2.6  1¹ 22.5¹ — (100:0)  CE21 23.2 — 270 43.2 3.2  0.7¹ 1.1¹  0.4² 9.2³ (100:0)  E1 23.2 — 270 54.6  0.89  0.98¹ 0.67¹ — 2.9³ (73.8:26.2) E2 23.2 0.82 270 44.6 3.1  1¹ 0.73¹ — 0.81³ (65.9:44.1) E3 23.2 4.73 270 34.8 7.2  1.22¹ 10.04¹ — 0.42³ (51.6:48.4) CE22 23.2 12.74  270 34.9 6.6  6.3¹ 52.6¹ 28.2² 0.51³  (0:100) CE23 19 — 250 39   4   11.6¹ 69.5¹ — —  (0:100) E4 23.2 1.04 270 41.1 — — —  4² — (81.1:11.9) E5 23.2 2.80 270 39.1 — — —  3.6² — (71.2:28.8) E6 23.2 7.34 270 37   — — — 11.7² — (45.2:54.8) CE24 23.2 — 270 52.2 0.8 —  0.9² — (100:0)  E7 23.2 — 270 43.6 — — —  1.4² — (75:25) ¹The glass laminates used in these examples have three layers of 0.76 mm thick ionomer sheets sandwiched between the two glass sheets; ²The glass laminates used in these examples have three layers of 0.84 mm thick ionomer sheets sandwiched between the two glass sheets; ³The ionomer sheets used in these examples have dimensions of 100 × 50 × 0.76 mm.

Examples E7-E26

12×12 in (305×305 mm) solar cell modules described in Table 4 are assembled and laminated by either Lamination Process 1 (Examples E7-16) or Lamination Process 2 (Examples E17-26), as described below. Layers 1 and 2 constitute the incident layer and the front-sheet encapsulant layer, respectively, and Layers 4 and 5 constitute the back-sheet encapsulant layer and the back-sheet, respectively, when applicable.

In Lamination Process 1, the component layers of the laminate are stacked to form a pre-lamination assembly. For the assembly containing a polymeric film layer as the outer surface layer, a cover glass sheet is placed over the film layer. The pre-lamination assembly is then placed within a Meier ICOLAM® 10/08 laminator (Meier laminator; Meier Vakuumtechnik GmbH, Bocholt, Germany). The lamination cycle includes an evacuation step (vacuum of 3 in Hg (76 mm Hg)) of 5.5 min and a pressing stage (pressure of 1000 mbar) of 5.5 min at a temperature of 145° C. The resulting laminate is then removed from the laminator.

In Lamination Process 2, the pre-lamination assembly is placed in a vacuum bag, which is sealed and a vacuum is applied to remove the air from the vacuum bag. The bag is placed into an oven and heated to a temperature of about 90° C. to about 100° C. for 30 min to remove air contained within the assembly. The assembly is then subjected to autoclaving at 140° C. for 30 min in an air autoclave to a pressure of 200 psig (14.3 bar). The air is cooled without further introduction of air to the autoclave. After 20 min of cooling and when the air temperature reaches less than about 50° C., the autoclave is vented and the vacuum bag containing the laminated assembly is removed from the autoclave. The resulting laminate is then removed from the vacuum bag.

TABLE 4 Sample Solar Cell Laminate Structure No. Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 E7, E17 Glass 1¹ Ionomer 1² Solar Cell 1³ E8, E18 Glass 2⁴ Ionomer 2⁵ Solar Cell 2⁶ E9, E19 Solar Cell 3⁷ Ionomer 4⁸ Glass 2 E10, E20 Glass 1 Ionomer 5⁹ Solar ACR 1¹¹ FPF¹² Cell 4¹⁰ E11, E21 Solar Cell Ionomer 6¹⁴ Glass 2 5¹³ E12, E22 Glass 1 Ionomer 7 Solar Cell 4 Ionomer 7 Glass 3¹⁵ E13, E23 Glass 1 Ionomer 8 Solar Cell 1 E14, E24 Solar Cell 5 Ionomer 1 Glass 2 E15, E25 Solar Cell 5 Ionomer 8 Glass 2 E16, E26 Glass 1 Ionomer 8 Solar Cell 4 Ionomer 4 FPF ¹Glass 1 is Starphire ® glass from the PPG Corporation. ²Ionomer 1 is a 60 mil (1.5 mm) thick embossed sheet made from the ionomer used E1. ³Solar Cell 1 is a 10 × 10 in (254 × 254 mm) a-Si based thin film solar cell with a 125 μm thick stainless steel substrate (U.S. Pat. No. 6,093,581, Example 1). ⁴Glass 2 is a clear annealed float glass plate layer (2.5 mm thick). ⁵Ionomer 2 is a 20 mil (0.51 mm) thick embossed sheet made from the ionomer used in E1. ⁶Solar Cell 2 is a 10 × 10 in (254 × 254 mm) CIS based thin film solar cell (U.S. Pat. No. 6,353,042, column 6, line 19). ⁷Solar Cell 3 is a 10 × 10 in (254 × 254 mm) CdTe based thin film solar cell (U.S. Pat. No. 6,353,042, column 6, line 49). ⁸Ionomer 4 is a 20 mil (0.51 mm) thick embossed sheet made from the ionomer used in E2. ⁹Ionomer 5 is a 20 mil (0.51 mm) thick embossed sheet made from the ionomer used in E3. ¹⁰Solar Cell 4 is a silicon solar cell made from a 10 × 10 in (254 × 254 mm) polycrystalline EFG-grown wafer (U.S. Pat. No. 6,660,930, column 7, line 61). ¹¹ACR 1 is a 20 mil (0.51 mm) thick embossed sheet derived from ethylene methacrylic acid copolymer containing 18 wt % of copolymerized units of methacrylic acid and having a MFR of 2.5 g/10 min (as determined in accordance with ASTM D1238 at 190° C., 2.15 kg). ¹²FPF is a corona surface treated Tedlar ® film (1.5 mil (0.038 mm) thick), a product of E.I. du Pont de Nemours and Company. ¹³Solar Cell 5 is a thin film solar cell supported on 12 × 12 in (305 × 305 mm) glass sheet (U.S. Pat. Nos. 5,512,107; 5,948,176; 5,994,163; 6,040,521; 6,137,048; and 6,258,620). ¹⁴Ionomer 6 is a 45 mil (1.14 mm) thick embossed sheet made from the ionomer used in E2. ¹⁵Glass 3 in a Solexia ™ solar control glass from the PPG Corporation (3 mm thick). 

1. A solar cell module comprising a solar cell layer and an ionomer sheet, wherein, (A) the solar cell layer comprises a single solar cell or a plurality of electrically interconnected solar cells and; (B) the ionomer sheet comprises a sodium/zinc mixed ionomer that is the neutralization product of a precursor acid copolymer; wherein the precursor acid copolymer comprises copolymerized units of an α-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt % of copolymerized units of an α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms, based on the total weight of the precursor acid copolymer; wherein the precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min, as determined in accordance with ASTM D1238 at 190° C. and 2.16 kg; and wherein said precursor acid copolymer, when neutralized to a level of about 40% to about 90%, based on the total number of the carboxylic acid groups present in the precursor acid copolymer, to comprise carboxylate groups and counterions that consist essentially of sodium ions, produces a sodium ionomer, said sodium ionomer having a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry in accordance with ASTM D3418; and wherein said sodium/zinc mixed ionomer comprises carboxylate groups and a mixture of counterions; said mixture of counterions consisting essentially of about 5 to about 95 equivalent % of sodium cations, and, complementarily, about 95 to 5 equivalent % of zinc cations, based on the total number of equivalents of carboxylate groups in the precursor acid copolymer.
 2. The solar cell module of claim 1, wherein the sodium/zinc mixed ionomer is the neutralization product of a precursor acid copolymer that has been neutralized to a level of about 30% to about 90 wt %.
 3. The solar cell module of claim 1, wherein the sodium/zinc mixed ionomer is the neutralization product of a precursor acid copolymer that has been neutralized to a level of about 40% to about 70%.
 4. The solar cell module of claim 1, wherein the sodium/zinc mixed ionomer has a melt flow rate of about 0.7 to about 25 g/10 min or less, when measured according to ASTM D1238 at 190° C. and 2.16 kg.
 5. The solar cell module of claim 1, wherein the precursor acid copolymer comprises about 20 to about 25 wt % of copolymerized units of the α,β-ethylenically unsaturated carboxylic acid.
 6. The solar cell module of claim 1, wherein the mixture of counterions consists essentially of about 50 to about 95 equivalent % of sodium cations, and, complementarily, about 5 to about 50 equivalent % of zinc cations.
 7. The solar cell module of claim 1, wherein the ionomer sheet is in the form of a monolayer sheet and consists essentially of the sodium/zinc mixed ionomer.
 8. The solar cell module of claim 1, wherein the ionomer sheet is in the form of a multilayer sheet and comprises two or more sub-layers, and wherein at least one of the sub-layers consists essentially of the sodium/zinc mixed ionomer and each of the other sub-layer(s) comprises a polymer selected from the group consisting of acid copolymers, ionomers of acid copolymers, poly(ethylene vinyl acetates), poly(vinyl acetals), polyurethanes, polyvinylchlorides, polyethylenes, polyolefin block copolymer elastomers, copolymers of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid ester, silicone elastomers, epoxy resins, and combinations of two or more thereof.
 9. The solar cell module of claim 1, wherein the ionomer sheet has a total thickness of about 1 to about 120 mils (about 0.025 to about 3 mm).
 10. The solar cell module of claim 1, wherein the ionomer sheet is directly laminated to the solar cell layer.
 11. The solar cell module of claim 1, wherein the solar cell layer has a front sun-facing side and a back non-sun-facing side.
 12. The solar cell module of claim 11, which comprises a front encapsulant layer laminated to the front sun-facing side of the solar cell layer and a back encapsulant layer laminated to the back non-sun-facing side of the solar cell layer, wherein one of the front and back encapsulant layers is the ionomer sheet and the other of the front and back encapsulant layers comprises a polymeric material selected from the group consisting of acid copolymers, ionomers of acid copolymers, poly(ethylene vinyl acetates), poly(vinyl acetals), polyurethanes, polyvinylchlorides, polyethylenes, polyolefin block copolymer elastomers, copolymers of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid ester, silicone elastomers, epoxy resins, and combinations thereof.
 13. The solar cell module of claim 12, which comprises two ionomer sheets, wherein each of the front and back encapsulant layers comprises one of the two ionomer sheets.
 14. The solar cell module of claim 11, further comprising an incident layer, wherein the incident layer is an outermost surface layer of the module and is positioned to the front sun-facing side of the solar cell layer.
 15. The solar cell module of claim 11, further comprising a backing layer, wherein the backing layer is an outermost surface layer of the module and is positioned to the back non-light receiving side of the solar cell layer.
 16. The solar cell module of claim 14, wherein the incident layer is selected from the group consisting of (i) glass sheets, (ii) polymeric sheets comprising a polymer selected from the group consisting of polycarbonates, acrylics, polyacrylates, cyclic polyolefins, polystyrenes, polyamides, polyesters, fluoropolymers, and combinations of two or more thereof, and (iii) polymeric films comprising a polymer selected from the group consisting of polyesters, polycarbonates, polyolefins, norbornene polymers, polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, polyurethanes, acrylics, cellulose acetates, cellophanes, silicones, poly(vinyl chlorides), fluoropolymers, and combinations of two or more thereof.
 17. The solar cell module of claim 15, wherein the backing layer is selected from the group consisting of (i) glass sheets, (ii) polymeric sheets, (iii) polymeric films, (iv) metal sheets, and (v) ceramic plates, and wherein the polymeric sheets comprise a polymer selected from the group consisting of polycarbonates, acrylics, polyacrylates, cyclic polyolefins, polystyrenes, polyamides, polyesters, fluoropolymers, and combinations or two or more thereof; and the polymeric films comprise a polymer selected from the group consisting of polyesters, polycarbonates, polyolefins, norbornene polymers, polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, polyurethanes, acrylics, cellulose acetates, cellophanes, poly(vinyl chlorides), fluoropolymers, and combinations of two or more thereof.
 18. The solar cell module of claim 11, wherein the solar cells are wafer-based solar cells selected from the group consisting of crystalline silicon and multi-crystalline silicone based solar cells.
 19. The solar cell module of claim 18, which consists essentially of, in order of position, (i) an incident layer, (ii) a front encapsulant layer laminated to the front sun-facing side of the solar cell layer, (iii) the solar cell layer, (iv) a back encapsulant layer laminated to the back non-sun-facing side of the solar cell layer, and (v) a backing layer, wherein one of the front and back encapsulant layers is the ionomer sheet.
 20. The solar cell module of claim 19, which comprises two of the ionomer sheets, wherein each of the front and back encapsulant layers comprises one of the two ionomer sheets.
 21. The solar cell module of claim 11, wherein the solar cells are thin film solar cells selected from the group consisting of amorphous silicon, microcrystalline silicon, cadmium telluride, copper indium selenide, copper indium/gallium diselenide, light absorbing dyes, and organic semiconductors based solar cells.
 22. The solar cell module of claim 21, which consists essentially of, in order of position, (i) an incident layer, (ii) a front encapsulant layer comprising the ionomer sheet, and (iii) the solar cell layer, wherein the solar cell layer further comprises a substrate upon which the thin film solar cells are deposited and the substrate is positioned such that the substrate is an outermost surface of the module and is positioned on the back non-sun-facing side of the solar cell layer.
 23. The solar cell module of claim 21, which consists essentially of, in order of position (i) the solar cell layer, (ii) a back encapsulant layer comprising the ionomer sheet, and (iii) a backing layer, wherein the solar cell layer further comprises a superstrate upon which the thin film solar cells are deposited and the superstrate is positioned such that the superstrate is an outermost surface of the module on the front sun-facing side of the solar cell layer.
 24. A process for preparing a solar cell module, comprising: (i) providing an assembly comprising all the component layers recited in claim 1 and (ii) laminating the assembly to form the solar cell module.
 25. The process of claim 24, wherein the laminating step is conducted by subjecting the assembly to heat and optionally vacuum or pressure. 